voith offshore solutions
TRANSCRIPT
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Solutions for Offshore Applications
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Products
• Variable Speed Drives
• Stoeckicht Epicyclic Gears
• Hydrodynamic Variable Speed Drives for Subsea
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The Variable Speed Planetary Gear VORECON
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VORECON Offshore Applications
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Vorecon M-VSD for Compressors
Vorecon gives 3 in 1: Speed variation (e.g. 60% to 105%)
Speed increase (e.g. 1800 rpm to 15000 rpm)
Lubrication of overall drive train
fixed speedne = 1500 rpm or
ne = 1800 rpm
variable speed need (governed by process)e.g. na = 15000 rpm
Vorecon does speed increase to MCS& creates variable speed, e.g. 60 to 105%
lubrication of overall drive train
6General Presentation | Products | Function
Vorecon FunctionBasic design of the Vorecon
Combination of hydrodynamic components and planetary gear in a common housing.
For powers of more than 1000 kW.
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VoreconFunction (I)
DriverDriven
machineGearbox
n1 = constant n2 = constanti0 = fixed
FIXED SPEED
n = speedi = gear ratio
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VoreconFunction (II)
DriverDriven
machineGearbox
VFD
n1 = variable n2 = variablei0 = fixed
VARIABLE SPEED WITH VFD(E-VSD)
n = speedi = gear ratio
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VoreconFunction (III)
DriverDriven
machineGearbox
n1 = constant n2 = variablei0 = variable
Hydrodynamic Drive
Vorecon
Epicyclic Gear
Torque Converter
VARIABLE SPEED WITH VORECON(M-VSD)
n = speedi = gear ratio
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VoreconTypes for Oil & Gas Applications
RWCSpeed control range 60 - 100 %
Fully unloaded motor start-up.Best for weak grids.
Applications:Compressors & Pumps
RWESpeed control range 60 - 100 %
Partially unloaded motor start-up.Best for strong to medium strong grids.
Applications:Compressors & Pumps
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Simplicity ...
- Integral step-up gear- Integral lube oil system
Standard fixed speed HV motor
Standard couplings
Voith Vorecon
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Aircondition
Grid filter
11 kV Transformer
Motor (6 kV)
Gearbox
Compressor / PumpSpecial
cabling
TransformerLube oil system
VFD
Motor (6 kV)
Gearbox
Compressor / Pump
Transformer
VFD
Harmonic-Filter
Special cabling
Lube oil system
Harmonic-Filter
... versus Complexity
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Aircondition
Grid filter
11 kV Transformer
Motor (6 kV)
Gearbox
Compressor / PumpSpecial
cabling
TransformerLube oil system
VFD
Motor (6 kV)
Gearbox
Compressor / Pump
Transformer
VFD
Harmonic-Filter
Special cabling
Lube oil system
Harmonic-Filter
Create Simplicity Use the Voith Vorecon
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Vorecon is a simple solution
• Compact
• Integrated lube oil system
• High efficiency
• Robust
• long-life
• High reliability
Motor (6 kV)
Motor (6 kV)
11 kV Sub Station
Compressor / Pump
Compressor / Pump
Motor (11 kV)
Motor (11 kV)
Integrated lube oil system
Integrated lube oil system
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Variable Frequency
Compressor Drive Train
Gas Coolers
Nitrogen
Harmonic Filters
Transformer
Ventilation VFD
Lube Oil System
General Persentation | Products | Advantages
Space requirement for Offshore VFD (12 – 14 MW)
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Variable Frequency
Harmonic Filters
Transformer
Ventilation VFD
General Persentation | Products | Advantages
Space requirement for Offshore VFD (12 – 14 MW)
21General Persentation | Products | Advantages
Space requirement for Offshore VFD (12 – 14 MW)
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Space requirement for Vorecon (11 – 14 MW)
Type RWE 12 F 7Power 11.000 kWSpeed ne = 1.782 rpm
Application: LP, MP, HP Compressors
Dresser Rand
Presalt FPSOs, Petrobras, Brazil
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Installation Example
Type RWE 11.5 F 7Power 8.700 kWSpeed na = 11.138 rpm
ne = 1.782 rpm
Application: Injection Compressor 300 to 550 bar3,500,000 Sm3/day
Dresser Rand
Cidade de Paraty FPSO
SBM long term lease to Petrobras Brazil
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Reliability
Reliability
(8 065 000 – 1 743) / 8 065 000 = 99.98 %*
MTBF (Mean Time Between Failure)
8 065 000 / 19 = 424 474 hours ~ 48 years*
MTTR (Mean Time To Repair)
1 743 / 19 = 91.74 hours ~ 4 days
Survey on Vorecon Reliability 2013201 units
600 kW up to 31 200 kW
495 rpm up to 16 735 rpm
Total operating hours 8 065 000 hours
Reported failures 19
Non-availability time 1 743 hours* Calculation based on machines in operation
What is the cost of a drive failure / unplanned downtime?
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Life Expectancy
Do you include a spare VFD drive in your LCC? Or at least a complete upgrade to a new generation?
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Voith guarantees spare parts availabilityfor 30 years and more ...
ask any VFD maker to supply semiconductors of today also within 10 years from now
Vorecon is designed for ...
a life time of more than 30 years tough environmental conditions, e.g. heat, cold, dust, explosion hazards
Life Expectancy
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Boiler feed pumps
Mannheim, Germany
Variable Speed
Planetary Gear Vorecon
Type: RW 14-12 F 7
Power: 8500 kW
Speed: 5000 rpm
Since 1989
No overhaul after 116,000 operating hours (Sep. 6th 2011)
Superior Reliability of Vorecon
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Sostanj Power plant
Slovenia
Power: 750 kW
Speed: 2950 rpm
working since 1955
This picture has been taken in summer 2010
Long Life
Superior Reliability of Voith Drives
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The World & VoreconA success story of a proven technology!
600x
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The World & Vorecon
VORECON installations by country of installation, September 2014
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Epicyclic Gear Units
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Product History
1932: BHS in Sonthofen was the birthplace of the Stoeckicht planetary gearbox.
At that date BHS acquired the first License Agreement followed by:
Allen Gears, UK in 1947
Alcatel (Flender), F in 1957
More than 5.500 Epicyclic Gear Units delivered.More than 80 Epicyclic Gear Units currently delivered per year.
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Characteristics of Epicyclic Gears
• Gear set consists of– sun gear– 3 up to 6 planet gears– pair of annuli
• Driving shaft and driven shaft are coaxial (no offset)
• Power transmission effected by several tooth contacts
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Epicyclic Gear Unit: Basic Data
• Stoeckicht load equalization
• Efficiency up to 99%
• Compact design
• Low weight
• Both connecting couplings can be integrated
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Summary features of Stoeckicht
• No bearing high speed side optimised load distribution (sun / planet) no power loss
no requirement for bearing oil
optimised efficiencyreduced oil flow
• Integrated high speed coupling
reduced interfaces / design clarification
reduced coupling costs
less clarification efforts
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Summary features of Stoeckicht
• Load distribution (3 – 6 planets) compact design
optimised weight
• Flexible annuli / movable and flexible coupling sleeves optimised load distribution planet gears to annuli
long service life
• Coaxial design of Epicyclic Gears smaller foundation
cost effective
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Epicyclic Gear UnitsLess Space Required – compact & coaxial design
• Average reduction of space approx. 20% (compared to parallel shaft gears)
– Coaxial shaft arrangement no horizontal offset!
– Smaller DBSE due to integrated couplings
• Smaller skid: lower weight
lower cost
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Better Efficiency
• Epicyclic gears:higher efficiencywith increasing ratio
• Efficiency up to 1.5% or higher !!!
advantage beginning with gear ratio i > 4
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+
+
+
+
+ Pitch line velocity:
Toothing Sleeve bearings
79.5 m/s
Technical Comparison: Parallel Shaft Gear Unit HD56-1 vs Epicyclic Gear Unit RTP50K
RTP50KHD56-1
Power: 5,900 kW Installation: Steam Turbine/Generator
Speeds: 10,680 / 1,500 rpm i = 7,12
53.7 m/s
7.85 m/s14.1 m/s
18.4 m/s
61.5 m/s
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Epicyclic Gear Unit – Parallel Shaft Gear Unit HD56-1- RTP50K (Technical Comparison)
Type HD 56-1 RTP 50KPower Loss 88 kW 65 kWEfficiency 98.6 - 0.1 % 99.0 - 0.1 %Oil Comsumption 130 l/min 140 l/minNoise 85 +/- 2 dB 85 +/- 2 dBWeight 4,700 kg 3,300 kg
Power: Turbine Speed: 5,900 kW 10,680 rpm
Installation: Generator Speed:Steam Turbine - Generator 1,500 rpm
41*Assumptions: 8,000 operating hours per year; 7 ct/kWh; 2% cost increase; $15 per kg saving; $2,000 per m² saving
FPSO application, Electrical Motor driven Compressor
Rated power of 10,200 kW, Speeds: 1,785 / 11,239 rpm
Economy of Epicyclic Gears (case study)
Par. ShaftGearbox
HD71-2
EpicyclicGearboxRTP56K
RelativeReduction Assumption Value
Footprint of skid 40.98 m2 32.20 m2 21% $2.000 per m² $17,360*
Weight of baseframe 24,000 kg 19,926 kg 17% $15 per kg $61,110*
Weight of gearbox reduction 8,600 kg 6,400 kg 26% $15 per kg $33,000*
Efficiency 98.1% 98.9% 8.000 h / year
Power loss 196 kW 105 kW $0,07/ kWh $50,288 *
Opex Savings over design life $1,221,866*
Capex savings $111.470Operational Costs
TOTAL Capex + Opex savings $1,333,336
Gearbox 100% 100% 0% $0
Capital Costs
(2% cost increase per year)
42POG Workshop 2014 | Sylvia Lux | 2014-05-19 - 2014-05-23
Example of application Vertical Epicyclic Gear box type RTG 36V
Power: 4,500 kW
Speeds: 7,151 / 1,800 rpm
Application: Between e-Motorand multi-phase
pump
Operator: Oil platformDunbar, UK
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Epicyclic Gear Units should be the first choice when,• gear ratio ≥ 6 high efficiency gearbox• highest reliability in operation required no high speed bearings, less pitch line
velocities • critical rotor dynamical behaviour of high speed side high speed turbines or
compressors• compact and light weight solution is required cost and space savings• input and output shafts shall have same direction of rotation• gearbox should work in both directions of rotation• coaxial design is needed• design to ISO and/or AGMA 2001 resp. 2101 is required API philosophy is also
possible by higher safety factors • parallel shaft gears can’t be used anymore (high speeds, high power
applications)
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Hydrodynamic Variable Speed Drive for Subsea Drivetrains
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Torque Converter for Subsea Pump Drives
- Constant speed, liquid filled motor
- Highly integrated variable speed Torque Converter with integrated speed increasing capability
- Single or multi phasepump / compressor
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Torque Converter for Subsea Pump Drives
- Compact VSD solution with reduced complexity and improved reliability
- Substitute for spacious topside equipment (VFD) or complex electrical subsea frequency converter
- Enabler for subsea boosting and water injection by reduced CAPEX (greenfield)
- Empowering enhanced oil and gas recovery by boosting or water injection for existing platforms due to less topside footprint (brownfield)
source: Fuglesangs Subsea
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VFD vs Torque Coverter for Subsea ApplicationsComplexity vs Simplicity!
VFD Competitor Solution VOITH Torque Converter
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